Battery Intermediate Lead Stress Isolation
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Solution Overview
Problem
Existing battery technologies face challenges in reliably joining current collecting tabs to terminal leads without damaging the gas-relief vent, as ultrasonic welding can transmit vibrations that compromise the vent's integrity, and resistance welding risks scattering aluminum materials.
Innovation Solution
The design incorporates an intermediate lead with a leg part that connects the electrode-group-joint part and the first lead-joint part on different planes, allowing independent joining of current collecting tabs using ultrasonic welding, and subsequent laser or resistance welding of the terminal lead, preventing stress transmission and ensuring the gas-relief vent's reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic joining is used to join current collecting tabs to terminal leads, then the joining strength and electrical connection are improved, but the gas-relief vent in the lid may be broken or deteriorated due to transmitted ultrasonic vibrations
Solution Approach 1:
The patent introduces an intermediate lead structure positioned between the current collecting tabs and the terminal lead. This intermediate lead acts as a mediator that receives ultrasonic vibrations from the current collecting tabs and dissipates them before they reach the terminal lead and lid assembly, thereby protecting the gas-relief vent while maintaining effective electrical connection.
Solution Approach 2:
The patent extracts the problematic ultrasonic vibration transmission path by separating the joining operation from the terminal lead connection. The current collecting tabs are joined to an intermediate structure first, and then this intermediate structure is connected to the terminal lead, removing the direct transmission path that would otherwise damage the gas-relief vent.
2Ease of manufacture
If resistance welding is used to join aluminum current collecting tabs, then the joining process is simplified, but the aluminum material tends to be scattered or flung off due to the high melting point oxide film on the aluminum surface
Solution Approach 1:
The patent replaces resistance welding (thermal process) with ultrasonic joining (mechanical vibration process). Ultrasonic joining uses high-frequency mechanical vibrations to create friction and heat at the contact interface, allowing aluminum materials to be joined without melting through the oxide film, thus preventing material scattering while maintaining process simplicity.
3Manufacturing precision
If laser joining is used to join current collecting tabs, then precise joining is achieved, but it is difficult to join multiple metal plates together to produce one member
Solution Approach 1:
The patent merges multiple current collecting tabs and the intermediate lead into a single integrated structure through ultrasonic joining. This approach allows multiple metal plates to be joined together as one member, overcoming the limitation of laser joining while maintaining precise alignment and connection quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the reliability of the gas-relief vent and reduces electrical resistance, enabling firm and low-resistance connections while maintaining the integrity of the gas-relief vent, thus improving the battery's overall performance.
Implementation Method 1
Ultrasonic joining is suitable in order to join the plurality of current collecting tabs together, and to join the plurality of current collecting tabs to a lead or the like connected to the outside of a battery container
Implementation Method 2
subsequent laser or resistance welding of the terminal lead
Implementation Method 3
The first lead-joint part and the electrode-group-joint part are located on planes different from each other, enabling independent joining operations that prevent stress transmission to the gas-relief vent
Implementation Method 4
enabling firm and low-resistance connections while maintaining the integrity of the gas-relief vent
Data Source
Figure 1
Figure 2
AI summary
In general, according to one embodiment, there is provided a battery (10). This battery (10) includes a container (1), a lid (2), a gas-relief vent (22), an electrode group (3), an intermediate lead (4), and a terminal lead (5). The gas-relief vent (22) is provided in the lid (2). The intermediate lead (4) includes a first lead-joint part (4b), an electrode-group-joint part (4a), and a leg part (4c). The leg part (4c) connects the first lead-joint part (4b) and the electrode-group-joint part (4a) to each other. The first lead-joint part (4b) and the electrode-group-joint part (4a) are located on planes different from each other.